Side impact control structure

ABSTRACT

A frame and support assembly for a vehicle lacking a conventional, separate B-pillar includes first and second frame members and a plurality of support assemblies. Each support assembly includes a plurality of bulkheads, a pair of outriggers, and a cross member. The bulkheads are incorporated into first and second side sill assemblies. The outriggers extend between the side sill assemblies and the first and second frame members. The cross members extend between the first and second first frame members.

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit of priority to U.S. ProvisionalApplication Ser. No. 60/419,638 filed Oct. 18, 2002, which is hereinincorporated by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention is generally directed toward vehicle frameassemblies and, more particularly, toward vehicle frame assembliesadapted to withstand side impacts.

2. Description of Related Art

Vehicles conventionally include a frame extending beneath the vehiclebody and associated structural supports to which the body panels andvehicle doors are secured. Such conventional structural supports includean A-pillar and a B-pillar. The A-pillar extends upwardly from adjacentthe front panel and attaches to a front corner of the vehicle roof. TheB-pillar conventionally extends upwardly from the side sill to the roofat a location relatively between the front and rear doors. The rear edgeof the front door seals against the B-pillar while the forward edge ofthe rear door, which is hingedly secured to the B-pillar, also sealsagainst the B-pillar. Recently, however, vehicle body styles have beenintroduced, wherein a conventional B-pillar is not provided.

In recent years, there has been an increased awareness of the need toprovide vehicles with improved protection from side impact collisions.Most efforts to provide such improved protection have been directedtoward improving the construction of vehicle doors or B-pillars, or byproviding side-mounted air bags. Examples of such efforts are shown inU.S. Pat. Nos. 6,474,721; 6,517,142; and 6,519,854. Some efforts toprovide improved protection against side impact collisions, however,have been directed toward strengthening the frame of the vehicle.Examples of such efforts are shown in U.S. Pat. Nos. 5,464,266 and5,921,618. In new vehicle body styles lacking a conventional B-pillar,it is especially desirable to provide a frame that is better able toabsorb side impact collisions. The present invention is directed to suchan improved frame.

SUMMARY OF THE INVENTION

The present invention is directed toward an improved progress crushassembly for a vehicle lacking a B-pillar that is particularly useful toabsorb side impacts. In accordance with the present invention, a frameand support structure for a vehicle having a longitudinal axis isprovided. The frame and support structure includes spaced-apart firstand second side sill assemblies and spaced-apart first and second framemembers, all of which extend longitudinally. The first and second framemembers are disposed between the first and second side sill assemblies.At least one lateral support assembly is provided and includes first andsecond outriggers and a cross member. The first and second outriggersextend between the first side sill assembly and the first frame member,and the second outrigger extends between the second side sill assemblyand the second frame member. The cross member extends between the firstand second frame members.

BRIEF DESCRIPTION OF THE DRAWINGS

These and further features of the invention will be apparent withreference to the following description and drawings, wherein:

FIG. 1 is schematic perspective view of portions of a vehicleincorporating an improved support assembly according to the presentinvention;

FIG. 2 is a schematic, partially exploded, perspective view of portionsof a vehicle incorporating the improved support assembly according tothe present invention, with the vehicle floor removed for purposes ofclarity;

FIG. 3 is a top schematic view of a frame assembly incorporating thesupport assemblies of the present invention;

FIG. 4 is a cross-sectional view of a side sill assembly and outriggeraccording to the present invention; and,

FIG. 5 schematically illustrates force transfer in a vehicleincorporating the support assembly of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Initially it is noted that the drawings referred to hereinafter asillustrating the preferred embodiments of the present invention are notto scale and are schematic in nature and, therefore, should not be takentoo literally. Nevertheless, the drawings illustrate the inventionsufficiently to enable one skilled in the art to practice the invention.

With reference to FIGS. 1-2, a vehicle body 10 incorporating a frame andsupport assembly according to the present invention is illustrated. Eachside of the vehicle body 10 includes an A-pillar 12, a side sillassembly 14, 16, a rear body panel 18, a front body panel 20, and a topbeam 22 that cooperate to define an enlarged door opening. A front door24 and a rear door 26 are shown in phantom in FIG. 1. Preferably, thefront door 24 is hingedly or pivotally secured to the front body panel20 while the rear door 26 is hingedly or pivotally secured adjacent therear body panel 22. When the front and rear doors 24, 26 are closed, therearward edge of the front door 24 preferably overlaps the forward edgeof the rear door 26. When the front and rear doors 24, 26 are open, theentire enlarged door opening is available for ingress and egress to andfrom the vehicle passenger compartment.

With further reference to FIG. 1, a vehicle floor 28 is shown, as wellas portions of a front, mid, and rear support assemblies 30, 32, 34. Thevehicle floor 28 overlies other portions of the frame and supportstructure that are not shown in FIG. 1, but rather are illustrated insubsequently-described drawing figures. The front support assembly 30 ispreferably disposed about mid-way along the length of the front door 24when the front door 24 is closed, and includes an upper beam member 36that extends between, and is secured to, the first and second side sillassemblies 14, 16 located on opposite sides of the vehicle, asillustrated. The mid support assembly 32 is preferably disposed about atthe joint or union of the front and rear doors 24, 26, and extendsacross the width of the vehicle. Similarly, the rear support assembly 34is preferably disposed at about midway along the length of the rear door26 when the rear door 26 is closed, and extends across the entire widthof the vehicle. Also illustrated in FIG. 1 is a roof arch 38 that isgenerally aligned with the mid support assembly 32. The roof arch 38extends between, and interconnects, the top beams 22 overlying the dooropenings. As will be described more fully hereinafter, the roof arch 38cooperates with the support assemblies 30, 32, 34 to absorb energydelivered to the vehicle during a side impact.

With reference to FIGS. 2 and 3, the vehicle frame and support structureaccording to the present invention is illustrated. The frame and supportstructure includes first and second generally U-shaped frame members 40,42 that extend longitudinally in the vehicle at laterally spaced-apartlocations. Preferably, the frame members 40, 42 have upwardly directedarms that are interconnected by a generally horizontal base member so asto define an upwardly open channel-like structure. Also, as will beappreciated from the drawings, the frame and support structure isgenerally symmetrical as viewed about a longitudinal centerline or axis44 of the vehicle.

The first frame member 40 is disposed on a first side of the vehicleaxis 44 so as to be relatively closer to the first side sill assembly14. Similarly, the second frame member 42 is disposed on an opposite orsecond side of the vehicle axis 44 so as to be relatively closer to asecond side sill assembly 16.

Each of the front, mid, and rear support assemblies 30, 32, 34 include aplurality of bulkheads 46, a pair of outriggers 48, and a cross member50 that cooperate to transfer energy from the side sill assembliestoward the frame members 40, 42, as will be described more fullyhereinafter. The bulkheads 46 of the support assemblies are incorporatedinto the first and second side sill assemblies 14, 16.

More specifically, the first and second side sill assemblies 14, 16 aregenerally identical to one another, and each includes a first or innerelongated side sill member 52 and a second or outer elongated side sillmember 54 mated to the first side sill member 52. A hollow area isdefined between the first and second elongated side sill members 52, 54.The bulkheads 46 of the front, mid, and rear support assemblies 30, 32,34 are disposed within the hollow area of the side sill assemblies 14,16. The bulkheads 46 are secured to, extend between, and interconnectthe inner and outer side sill members 52, 54 and, therefore, areoriented generally transverse to the vehicle axis 44. As shown in FIGS.2 and 4, each of the bulkheads 46 has a generally planar body portionthat substantially fills the cross-section of the hollow area of Itsrespective side sill assembly 14 or 16. One or more ribs may be formedin the body portion of each bulkhead 46 to rigidify the body portion.For more information related to side sill assemblies and bulkheads,reference should be made to commonly-assigned U.S. patent applicationSer. No.10/683776, filed Oct. 10, 2003, the disclosure of which isexpressly incorporated herein in its entirety.

In the illustrated and preferred embodiment, each end of the frontsupport assembly 30 includes a pair of bulkheads 46 disposed between theouter side sill member 54 and the inner side sill member 52. Similarly,each end of the mid support assembly 32 includes a single bulkhead 46disposed between the inner and outer side sill members 52, 54, and eachend of the rear support assembly 34 includes a pair of bulkheads 46between the inner and outer side sill members 52, 54. The bulkheads 46serve to stiffen the side sill assemblies 14, 16, and to transfer energyfrom the outer side sill members 54 to the inner side sill members 52and, ultimately, to the outriggers 48, frame members 40, 42, and crossmember 50, as will be apparent from the following description.

The outriggers 48 extend between the inner side sill member 52 and theassociated first or second frame member 40, 42 and are oriented in adirection generally transverse to the vehicle axis 44 and the framemembers 40, 42 and generally parallel to the bulkhead 46. The outriggers48 are preferably generally U-shaped in cross section, havingupwardly-directed arms that are connected to one another by a base wallat a lower end thereof. Ends of the outriggers 48 are secured to theassociated frame member 40, 42 and inner side sill member 52 byconventional mechanical techniques, including welding and mechanicalfasteners, as appropriate. If desired, the outrigger ends may includeoutwardly extending wings or flanges that would abut and/or overlieportions of the associated frame member 40, 42 and inner side sillmember 52 so as facilitate attachment thereto.

The support assemblies' cross members 50 extend between and interconnectthe first and second frame members 40, 42. The cross members 50 arepreferably U-shaped in cross section so as to have a pair of upstandingarms that are interconnected at their bottom ends by a base member. Endsof the cross members 50 are secured to the associated frame member 40,42 by conventional mechanical techniques, including welding andmechanical fasteners, as appropriate. If desired, the cross member endsmay include outwardly extending wings or flanges that would abut and/oroverlie portions of the frame members 40, 42 so as facilitate attachmentthereto.

The first and second frame members 40, 42, as described hereinbefore,are generally U-shaped in cross section and extend generally parallel tothe vehicle axis 44. At locations aligned with the cross members 50, thefirst and second frame members receive braces 56 between theirupstanding arms. The braces 56 help to reinforce the frame members 40,42 and to transfer forces from one frame member arm to the other framemember arm.

As illustrated in the drawings, the bulkheads 46, outriggers 48, andcross member 50 for each of the support assemblies 30, 32, 34 arealigned with one another transverse to the vehicle axis 44, and defineload paths through which forces may be communicated when the vehicleexperiences a side impact. While these load paths communicate forcesinwardly from the outer portions of the vehicle, the strength orstiffness of the components of the support assemblies are designed todeform or crush in a predetermined and controlled fashion so that theinnermost portions of the frame and support structure, namely the framemembers 40, 42 and cross members 50, will ordinarily retain theirstructural integrity and remain undeformed in a crash.

More specifically, the components of the support assemblies 30, 32 34are designed to have relatively different stiffnesses or strengths so asto provide a progressive, controlled crushing function during a sideimpact. More specifically, the bulkheads 46, and the first and secondside sill assemblies 14, 16 into which they are incorporated, arerelatively weaker or less stiff as compared to the outriggers 48, whilethe outriggers 48 are relatively weaker or less stiff as compared to theframe members 40, 42 and the cross members 50. Accordingly, during arelatively low-speed side impact, the bulkheads 48 and side sill members52, 54 may buckle or crush, while the outriggers 48, frame members 40,42, and cross members 50 will be unaffected. In a moderate speed sideimpact, the bulkheads 46, side sill assemblies 12, 14, and outriggers 48will deform, while the frame members 40, 42 and the cross members 50will be unaffected. As will be appreciated by those skilled in the art,the position and strength of the cross members 50 serve to share thecrash energy that is not absorbed by the bulkheads 46 and outriggers 48between the first and second frame members 40, 42, and will only bedeformed or affected in the most serious or highest-energy side impacts.

In order to facilitate transfer of loads between the first and secondside sill assemblies 14, 16, the support assemblies 30, 32, 34, and theroof arch 38, the rear door 26 preferably includes a vertically orientedbeam 58 adjacent its forward edge. Upper and lower latching assemblies60, 62 disposed at upper and lower ends of the rear door beam 58interconnect the rear door beam 58 with the associated side sillassembly 14, 16 and the top beam 22, respectively. Accordingly, during aside impact, the rear door beam 58 serves as a load path thatdistributes a portion of the energy to the roof arch 38, therebyreducing the load that must be born by the frame members 40, 42 andsupport assemblies 30, 32, 34, described hereinbefore. In this regard,the rear door beam 58 together with the upper and lower latchingassemblies 60, 62 may be considered to be a substitute for theconventional B-pillar. This energy transfer and distribution isillustrated schematically in FIG. 5.

It is noted that the height of the frame members 40, 42 varies overtheir length. More specifically, the frame members have a reduced heightportion at a forward end thereof. This reduction in height facilitatesplacement of the front support assembly top beam member 36 over thevehicle floor 28, as illustrated in FIG. 1. As set forth above, thevehicle floor 28 is disposed over the outriggers 48 and the crossmembers 50 of the support assemblies, as well as the first and secondframe members 40, 42.

While the preferred embodiments of the present invention have beendescribed with particularity herein, it is considered apparent that thepresent invention is capable of numerous modifications, replacements,and substitutions of parts and, therefore, is not to be limited to thestructure specifically described and illustrated. Rather, the presentinvention is only to be defined by the claims appended hereto, includingequivalents thereof.

1. A frame and support structure for a vehicle having a longitudinalaxis, said frame and support structure comprising: spaced-apart firstand second side sill assemblies extending generally parallel to thelongitudinal axis of the vehicle; spaced-apart first and second framemembers extending generally parallel to the longitudinal axis of thevehicle, said first and second frame members being disposed between thefirst and second side sill assemblies; and, at least one lateral supportassembly that includes: first and second outriggers, said firstoutrigger extending between the first side sill assembly and the firstframe member, wherein opposing ends of the first outrigger are securedto the first side sill assembly and the first frame member,respectively, and said second outrigger extending between the secondside sill assembly and the second frame member, wherein opposing ends ofthe second outrigger are secured to the second side sill assembly andthe second frame member, respectively; a cross member extending betweenthe first and second frame members, wherein opposing ends of the crossmember are secured to the first and second frame members, respectively;and a first bulkhead disposed in the first side sill assembly and asecond bulkhead disposed in the second side sill assembly.
 2. The frameand support structure according to claim 1, wherein the at least onelateral support assembly comprises front, mid and rear supportassemblies.
 3. The frame and support structure according to claim 1,wherein the cross member is aligned with the first and secondoutriggers.
 4. The frame and support structure according to claim 3,wherein each of the first and second frame members is generally U-shapedand includes a pair of spaced-apart arms, between which are disposed apair of braces that are aligned with the cross member.
 5. The frame andsupport structure according to claim 1, wherein the first and secondside sill assemblies each comprise inner and outer side sill memberswith a hollow area defined therebetween, and wherein the first bulkheadis secured between the inner and outer side sill members of the firstside sill assembly and the second bulkhead is secured between the innerand outer side sill members of the second side sill assembly.
 6. Theframe structure according to claim 5, wherein the at least one lateralsupport assembly comprises front, mid and rear support assemblies. 7.The frame and support structure according to claim 6, wherein the frontand rear support assemblies each further comprise a third bulkheaddisposed proximate to, but spaced from, the first bulkhead, and a fourthbulkhead disposed proximate to, but spaced from, the second bulkhead. 8.The frame and support structure according to claim 7, wherein the frontsupport assembly further comprises an upper beam member that extendsbetween the first and second side sill assemblies.
 9. The frame andsupport structure according to claim 1, wherein the first and secondoutriggers each have a generally U-shaped cross-section.
 10. The frameand support structure according to claim 9, wherein the cross member hasa generally U-shaped cross-section.
 11. A vehicle having a longitudinalaxis, said vehicle comprising: front and rear doors, each of which ismovable between open and closed positions; spaced-apart first and secondside sill assemblies disposed below the front and rear doors andextending generally parallel to the longitudinal axis of the vehicle;spaced-apart first and second frame members extending generally parallelto the longitudinal axis of the vehicle, said first and second framemembers being disposed between the first and second side sillassemblies; and, at least one lateral support assembly that includes:first and second outriggers, said first outrigger extending between thefirst side sill assembly and the first frame member, wherein opposingends of the first outrigger are secured to the first side sill assemblyand the first frame member, respectively, and said second outriggerextending between the second side sill assembly and the second framemember, wherein opposing ends of the second outrigger are secured to thesecond side sill assembly and the second frame member, respectively; across member extending between the first and second frame members,wherein opposing ends of the cross member are secured to the first andsecond frame members, respectively; and a first bulkhead disposed in thefirst side sill assembly and a second bulkhead disposed in the secondside sill assembly.
 12. The vehicle according to claim 11, wherein theat least one lateral support assembly comprises front, mid and rearsupport assemblies, said front and rear support assemblies being alignedwith the front and rear doors, respectively, and said mid supportassembly being disposed at a juncture between the front and rear doorswhen the front and rear doors are in the closed positions.
 13. Thevehicle according to claim 11, wherein the cross member is aligned withthe first and second outriggers.
 14. The vehicle according to claim 13,wherein each of the first and second frame members is generally U-shapedand includes a pair of spaced-apart arms, between which are disposed apair of braces that are aligned with the cross member.
 15. The vehicleaccording to claim 11, wherein the first and second side sill assemblieseach comprise inner and outer side sill members with a hollow areadefined therebetween, and wherein the first bulkhead is secured betweenthe inner and outer side sill members of the first side sill assemblyand the second bulkhead is secured between the inner and outer side sillmembers of the second side sill assembly.
 16. The vehicle according toclaim 15, further comprising a floor, and wherein the front supportassembly further comprises an upper beam member that is disposed overthe floor and extends between the first and second side sill assemblies.17. The vehicle according to claim 11, wherein the front and rear doorsare disposed on one side of the longitudinal axis of the vehicle, andwherein the vehicle further comprises a front body panel disposedforward of the front door, a rear body panel disposed rearward of therear door and a top beam disposed above the front and rear doors, andwherein the front body panel, the rear body panel and the top beamcooperate to help define an enlarged door opening.
 18. The vehicleaccording to claim 17, wherein the front door is pivotally secured tothe front body panel and the rear door is pivotally secured to the rearbody panel, and wherein when the front and rear doors are in the openpositions, the enlarged door opening is available for ingress and egressto and from the vehicle.
 19. The vehicle according to claim 18, furthercomprising a roof arch secured to the top beam, and wherein the reardoor further comprises a vertically-oriented beam that is aligned withthe roof arch when the rear door is in the closed position.
 20. Thevehicle according to claim 19, further comprising upper and lowerlatching assemblies that connect the top beam and one of the first andsecond side sill assemblies to the beam of the rear door, respectively,when the rear door is in the closed position.
 21. The vehicle accordingto claim 20, further comprising another pair of front and rear doors andanother top beam, all of which are disposed on the other side of thelongitudinal axis of the vehicle, and wherein the roof arch extendslaterally across the vehicle and is secured between the top beams.
 22. Avehicle having a longitudinal axis, said vehicle comprising: front andrear doors, each of which is movable between open and closed positions;a floor; spaced-apart first and second side sill assemblies disposedbelow the front and rear doors and extending generally parallel to thelongitudinal axis of the vehicle; spaced-apart first and second framemembers disposed below the floor and extending generally parallel to thelongitudinal axis of the vehicle, said first and second frame membersbeing disposed between the first and second side sill assemblies; and, alateral support assembly that includes: first and second outriggersdisposed below the floor, said first outrigger extending between thefirst side sill assembly and the first frame member, and said secondoutrigger extending between the second side sill assembly and the secondframe member; a cross member disposed below the floor and extendingbetween the first and second frame members; an upper beam member that isdisposed over the floor and extends between the first and second sidesill assemblies; and a first bulkhead disposed in the first side sillassembly and a second bulkhead disposed in the second side sillassembly.
 23. The vehicle of claim 22, wherein opposing ends of thecross member are secured to the first and second frame members,respectively, and wherein opposing ends of the first outrigger aresecured to the first side sill assembly and the first frame member,respectively, and wherein opposing ends of the second outrigger aresecured to the second side sill assembly and the second frame member,respectively.
 24. The vehicle according to claim 23, wherein the crossmember is aligned with the first and second outriggers.
 25. The vehicleaccording to claim 24, wherein each of the first and second framemembers is generally U-shaped and includes a pair of spaced-apart arms,between which are disposed a pair of braces that are aligned with thecross member.
 26. The vehicle according claim 22, wherein the front andrear doors are disposed on one side of the longitudinal axis of thevehicle, and wherein the lateral support assembly is a front lateralsupport assembly that is disposed about midway along the length of thefront door when the front door is in the closed position.
 27. Thevehicle according to claim 26, further comprising: a mid supportassembly disposed at a juncture between the front and rear doors whenthe front and rear doors are in the closed positions; and a rear supportassembly disposed about midway along the length of the rear door whenthe rear door is in the closed position; and wherein the mid and rearsupport assemblies each comprise: first and second outriggers disposedbelow the floor, said first outrigger extending between the first sidesill assembly and the first frame member, and said second outriggerextending between the second side sill assembly and the second framemember; a cross member disposed below the floor and extending betweenthe first and second frame members; and a first bulkhead disposed in thefirst side sill assembly and a second bulkhead disposed in the secondside sill assembly.